Integrated reel hub and motor shaft assembly for tape drives

ABSTRACT

An integrated reel hub and motor shaft assembly for a tape drive that limits axial and radial run-out of tape (e.g., magnetic, optical) relative to a read/write head assembly and the various errors (e.g., loading, tension, reading, writing, and the like) associated therewith. In one arrangement, a reel hub of a reel assembly is directly molded (e.g., via an injection molding process) onto and around an end of a drive or motor shaft of a drive assembly. As a result, a more consistent head to tape interface, greater tape tracking performance, increased track density, and the like may be achieved.

BACKGROUND

1. Field of the Invention

The present invention generally relates to the winding of tape aroundreels in a tape drive and, more particularly, to an integrated reel huband motor shaft assembly and fabrication method therefore that reduceradial and axial run-out of the tape relative to the reel hub to limitposition errors and head-to-tape spacing complications.

2. Relevant Background

Tape drives have been widely employed in industry for over thirty yearsdue to their ability to store large amounts of data on a relativelysmall and inexpensive removable format. Typically, tape drives use astorage tape having a thin film of magnetic material which is woundbetween a pair of tape reels as data is transferred to or from the tapemedia via a read/write tape head assembly. In one arrangement, one ofthe reels (e.g., the “take-up” reel) is part of the tape drive while theother reel (e.g., the “cartridge” reel) is part of a removablecartridge. Upon insertion of the cartridge into the tape drive, thestorage tape on the cartridge reel must be coupled to the take-up reelof the tape drive (e.g., via respective leaders). After coupling, thetape is unwound from the cartridge reel, moved past the tape headassembly and wound onto the take-up reel via a drive motor. Next, thetape is unwound from the take-up reel, moved past the tape head assemblyand wound onto the cartridge. Subsequently, the storage tape must beuncoupled from the take-up reel, prior to removing the cartridge fromthe tape drive. In another arrangement, both reels are part of acassette which is inserted into a tape drive and driven by a drivemotor.

More recently, a popular trend is towards multi head, multi-channelfixed head structures with narrowed recording gaps and data track widthsso that many linear data tracks may be achieved on a tape medium of apredetermined width, such as one-half inch width tape. To increase thestorage density and reduce access time of magnetic tapes, data tracks onthe tape are arranged with greater density and the tape is streamed by atape head at increasingly faster rates.

However, increased storage density and linear speed can lead to highererror rates when reading and/or writing on the tape due to both “axial”and “radial” run-out. Axial run-out refers to lateral or transversemotion of the tape on the reel assembly relative to a head assembly in atape drive as the tape streams by the head assembly, and is generallydefined as the peak-to-peak distance of the undesirable movement(in-plane) of the tape perpendicular to its prescribed longitudinaldirection of motion past the head assembly. Radial run-out refers totension variations in the tape in a direction perpendicular to the axisof rotation of the reel assembly.

Often, axial and radial run-out are caused by various fabrication andassembly tolerances in the engagement between a reel assembly and acorresponding drive assembly (e.g., reel driver, drive shaft). If theengagement is imprecise because of an offset (e.g., in the axial and/orradial directions), the tape path may vary resulting in excess lateraltape motion and/or tension variations in the tape. Both axial andlateral run-out can cause errors in the reading and/or writing processby limiting the degree to which a head assembly can locate a particulardata track. As a result, axial and radial run-out and the ability tocompensate for the same are major limiting factors in determining theminimum width of a track and the minimum spacing between tracks on thetape. As run-out is reduced, tracks may be stored more densely on thestorage tape and storage tape capacity can be increased.

The common approach to limiting axial and radial run-out is by way ofimproving the fabrication and/or assembly tolerances of and/or betweenthe reel and motor assemblies to allow for a more precise engagementbetween the same. In some arrangements, the reel and drive assemblieshave corresponding apertures through which fasteners can be insertedand/or threaded to limit relative movement. In other arrangements,corresponding interlock components (e.g., teeth, splines, and the like)may be disposed on the reel and drive assemblies and which mayrespectively interlock to limit relative movement between the reel anddrive assemblies. However, even relatively small mismatches in thematched features or teeth can cause run-out control and axial locationdifficulties. Furthermore, less than full engagement between the reeland drive assemblies can cause various types of tape loading or tensionerrors to occur and possibly lead to increased lateral tape motion. Inthis regard, the tolerance “stack-up” between the reel assembly, thedrive assembly, and the like can cause various types of errors inreading and/or writing processes and hinder the pursuit of increasedmagnetic tape data density.

SUMMARY

Disclosed herein is an integrated reel and drive assembly that serves toreduce the aforementioned tolerance stack-up to further limit and reduceaxial and radial tape run-out in tape drives and the various types oferrors (e.g., loading, tension, reading, writing, and the like)associated therewith. Broadly, the disclosed arrangement includes a reelhub of a reel assembly that is precisely molded (e.g., injection molded)directly onto a motor shaft of a drive or motor assembly (e.g., asopposed to separately fabricating the reel hub and then securing thesame to the motor shaft via bolts or other fasteners). In onearrangement, an inner surface of a central portion of the reel hub maybe in direct contact (e.g., free of gaps) with an end of the motorshaft. For instance, the disclosed integrated assembly may form part ofa take-up reel of a tape drive, where the take-up reel includes upperand lower flanges interconnected to opposing sides of the integratedreel hub that serve to contain the tape wound around the hub. Theresulting integrated assembly is largely devoid of many of thefabrication and assembly tolerances associated with the need tointerconnect a drive shaft and a separately fabricated reel hub. Thus,many of the above-mentioned errors can be limited or reduced leading toa more consistent head to tape interface, greater tape trackingperformance, increased track density, and the like.

In one arrangement, a custom-designed mold (e.g., die) may be sized andshaped to allow for the molding of a reel hub onto the end of a driveshaft of a motor assembly. The mold may include a movable portion (e.g.,platen) that is movable towards and away from a stationary portion(e.g., platen) so as to selectively form a reel hub cavity having theshape and size of the reel hub to be formed therebetween. The movableportion may have an elongated aperture that is sized and shaped toreceive the drive shaft so as to position an end of the drive shaftwithin the reel hub cavity upon the movable portion being moved intoengagement with or at least adjacent to the stationary portion. Anyappropriate resin or material (e.g., thermosetting, thermoplastic) maybe fed into the cavity (e.g., forced into the cavity as part of aninjection molding process) and allowed to cool to harden into theconfiguration of the cavity and thus a reel hub. Upon cooling andhardening of the molding material, the integrated reel hub and driveshaft assembly may be removed from the mold (e.g., via separating themovable portion from the stationary portion and ejecting the integratedassembly from the movable portion) any appropriate portions of a rotorassembly (e.g., rotor part, ball bearing assembly, and/or the like) maybe non-rotatably secured to (e.g., pressed over) the drive shaft.

For instance, the inner diameter of the aperture in the movable portioninto which the drive shaft is placed may be substantially the same as(e.g., slightly larger than) an inner diameter of an aperture throughthe rotor part and ball bearing assembly that is to be pressed over thedrive shaft. In other words, the outer surface of the drive shaft may bepositioned relative to an inner surface of the aperture in the movableportion during the molding process in a manner that substantially mimicsthe positioning of the outer surface of the drive shaft relative to aninner surface of the rotor part and ball bearing assembly once the rotorpart and ball bearing assembly are pressed over the drive shaft. In thisregard, the reel hub may be more precisely molded over the end of thedrive shaft so as to be spun by the drive shaft via the rotor part andball bearing assembly in a manner that is substantially free of wobbleand/or other inefficiencies In one aspect, a method for fabricating anapparatus for a tape drive includes providing a motor shaft having firstand second ends and a rotational axis extending between the first andsecond ends, and molding a hub of a reel assembly to the first end ofthe motor shaft to form an integral piece with the motor shaft. Afterthe molding, the hub includes an outer circumferential surface that isadapted to receive a tape pack thereon and a rotational axis that iscollinear with the rotational axis of the motor shaft.

In another aspect, an apparatus for a tape drive includes a motor shafthaving first and second ends and a rotational axis extending between thefirst and second ends, where the motor shaft is adapted to be rotatedabout the rotational axis by a motor. The integrated assembly alsoincludes a reel hub having an outer circumferential surface, a centralportion, and a rotational axis that is collinear with the rotationalaxis of the motor shaft and that passes through the central portion,where the outer circumferential surface is adapted to receive a tapepack thereon. The central portion of the reel hub has an inner surfacethat is in direct and rigid contact with the first end of the motorshaft.

In a further aspect, a tape drive includes a housing, a motor having astator non-rotatably secured to the housing and a rotor rotatablyinterconnected to the stator, a motor shaft non-rotatably secured to therotor, and a reel hub that is adapted to receive a tape pack thereon andthat is molded directly onto an end of the motor shaft. Passing acurrent through a conductor of the motor generates a force that rotatesthe rotor which induces a corresponding rotation of the reel hub via themotor shaft.

Any of the embodiments, an arrangements, or the like discussed hereinmay be used (either alone or in combination with other embodiments,arrangement, or the like) with any of the disclosed aspects. Merelyintroducing a feature in accordance with commonly accepted antecedentbasis practice does not limit the corresponding feature to the singular.Any failure to use phrases such as “at least one” does not limit thecorresponding feature to the singular. Use of the phrase “at leastgenerally,” “at least partially,” “substantially” or the like inrelation to a particular feature encompasses the correspondingcharacteristic and insubstantial variations thereof. Furthermore, areference of a feature in conjunction with the phrase “in oneembodiment” does not limit the use of the feature to a singleembodiment.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thedrawings and by study of the following descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a tape drive according to one embodiment.

FIG. 2 is a partial perspective, sectional view illustrating theengagement between a take-up reel and a separate rotor assembly of amotor assembly that is adapted to rotate the take-up reel according tothe prior art.

FIG. 3 is a partial perspective, sectional view illustrating anintegrated reel hub of a take-up reel and a motor shaft of a motorassembly that may be mounted within the tape drive of FIG. 1, accordingto one embodiment.

FIG. 4 is a flow diagram illustrating a method of fabricating theintegrated assembly of FIG. 3, according to one embodiment

FIG. 5 is a sectional view of a portion of a die that may be used todirectly mold the reel hub of FIG. 3 onto an end of the motor shaft,according to one embodiment.

DETAILED DESCRIPTION

Disclosed herein is a reel hub that is integrally formed onto an end ofa motor or drive shaft so as to form a single integrated piece with themotor shaft. The integrated reel hub and motor shaft assembly may formpart of a take-up reel in a tape drive to reduce or limit axial andradial run-out of magnetic tape as the tape is wound onto the reel hub.Integrating the reel hub and the motor shaft serves to eliminate or atleast reduce much of the tolerance stack-up made up of varioustolerances resident within the fabrication and assembly of current reeland motor assemblies. In this regard, many of the errors (e.g., loading,tension, reading, writing, and the like) resulting from both axial andradial tape run-out can be limited or reduced leading to a moreconsistent head to tape interface, greater tape tracking performance,increased track density, and the like.

Before discussing particulars of the disclosed integrated reel hub andmotor shaft assembly in more detail, reference will initially be made toFIG. 1 which illustrates one type of tape drive 10 in which thedisclosed integrated assembly may be implemented. Discussion of the tapedrive 10 of FIG. 1 is merely provided to assist the reader inunderstanding one specific context in which the disclosed integratedassembly can be used. In this regard, it should be understood that thedisclosed integrated assembly can be utilized in numerous other contexts(e.g., different types of tape drives, cartridges, cassettes, and thelike) where reduction of axial and/or radial tape run-out is desired.

Broadly, the tape drive 10 is operable to write data to and/or read datafrom a supply reel 18 of tape 16 (e.g., magnetic tape) of a tapecartridge 12. The tape drive 10 may have a take-up reel 20 that isrotatably supported on a drive body or housing 22. A drive leader 24 ofthe take-up reel 20 may be attachable to a cartridge leader 14 of thetape cartridge 12 so as to pull the cartridge leader 14 and tape 16along a tape path 26 to the take-up reel 20. The drive leader 24,cartridge leader 14 and tape 16 are configured to wrap around a reel hub27 of the take-up reel 20 such that the tape 16 and leaders 14 and 24form a tape pack.

The tape drive 10 may further include one or more guide members, such asrollers 28, for guiding movement of the drive leader 24, cartridgeleader 14 and tape 16 along the tape path 26. Additionally, the tapedrive 10 may also include one or more magnetic heads 30 (e.g., a “headassembly”) for performing read and/or write operations on the tape 16, amotor 32 for driving the take-up reel 20 (e.g., having a stator that isnon-movably secured to the housing 22, and a rotor that is rotatablypositioned relative to the stator and that is rotated upon passing acurrent through a conductor of the stator), and a cartridge receiver 34for receiving the tape cartridge 12. Furthermore, the cartridge receiver34 may include a motor 36 that is configured to drive the supply reel 18of the tape cartridge 12. Rollers 28, magnetic heads 30, motors 32 and36, and cartridge receiver 34 may be mounted in and supported by thehousing 22.

With reference now to FIG. 2, a partial perspective, sectional view ofan arrangement 100 made up of a take-up reel assembly 104 and a rotorassembly 108 according to the prior art is illustrated. The rotorassembly 108 includes a rotor 112 having a central aperture 116 throughwhich a motor shaft 120 having opposed first and second ends 124, 128 isreceived and non-movably (rigidly) secured or positioned. The rotorassembly 108 forms part of a motor (not shown) having a stator assembly(not shown) that, when energized with a current, is adapted to inducerotation of the rotor assembly 108. The take-up reel assembly 104includes a reel hub 132 having a circumferential wall 136 with an outersurface 137 on which a tape pack (i.e., length of tape, not shown) maybe wound, in addition to a central plate 138 that is generallyperpendicularly disposed relative to the circumferential wall 136.Furthermore, first and second flanges 140, 144 are respectively securedto first and second opposing sides 148, 152 of the reel hub 132 (e.g.,opposed sides of the circumferential wall 136) that serve to contain thetape pack therebetween.

To secure the take-up reel assembly 104 to the rotor assembly 108 (toallow the rotor assembly to induce a corresponding rotation of thetake-up reel assembly 104), a number of corresponding engagementcomponents or features are provided on the arrangement 100. First, thecentral plate 138 of the reel hub 132 includes a raised, central portion156 having a cavity 160 therewithin that is sized and shaped to belocated over the first end 124 of the motor shaft 120 to center thetake-up reel assembly 104 over the rotor assembly 108. Furthermore, thecentral plate 138 of the reel hub 132 and a top surface 168 of the rotor112 include a number of pairs of aligned apertures 172, 176 throughwhich respective fasteners 180 (e.g., bolts) may be threaded orotherwise inserted to non-rotatably secure the take-up reel assembly 104to the rotor assembly 108.

Previous reel/motor arrangements, such as the arrangement 100 of FIG. 2,introduce a number of inefficiencies and design flaws leading to axialand radial run-out of the tape pack and resultant errors in loading,tension, reading, writing, and the like. As seen in FIG. 2, a gap orclearance 164 must be left between the central portion 156 of the reelhub 132 and the first end 124 of the motor shaft 120 to allow forrelative movement between the motor shaft 120 and the reel hub 132during fastening of the reel hub 132 to the rotor 112. However, theclearance 164 necessarily introduces a tolerance into the assembly andengagement of the central portion 156 and the first end 124 motor shaftwhich can cause run-outs of the tape pack as it moves through the tapedrive. Furthermore, the various pairs of apertures 172, 176 andrespective fasteners 180 introduce additional assembly tolerancesbetween the central plate 138 and the rotor 112. In conjunction with theaforementioned assembly tolerances, numerous tolerances inherently existin the fabrication of the various components of the arrangement 100(e.g., in the dimensions of the reel hub 132, the rotor 112, the motorshaft 120, and the like). The overall tolerance stack-up of thearrangement 100 can lead to axial and radial run-out of the tape packand various resultant tape drive errors in loading, tension, reading,writing, and the like.

In this regard, FIG. 3 illustrates an arrangement 200 made up of atake-up reel assembly 204 and a rotor assembly 208, where thearrangement 200 includes an integrated assembly or apparatus 218 (madeup of a reel hub 232 directly molded onto a motor shaft 220, discussedin more detail below) that serves to eliminate or at least reduce manyof the above-discussed assembly and fabrication tolerances in previousdesigns and the attendant errors associated therewith. For instance, therotor assembly 208 may include a rotor 212 having a rotor part 213 witha central aperture 214 along with a magnet or magnetic assembly 215secured about an outer surface of the rotor part 213. The rotor assembly208 may also include a ball bearing assembly 216 having a centralaperture 217. The central apertures 214, 217 of the rotor part 213 andball bearing assembly 216 may be pressed over an outer (e.g.,circumferential) surface 221 of a motor shaft 220 (having opposed firstand second ends 224, 228) so as to be non-movably (e.g., non-rotatably)positioned relative thereto. For instance, the inner diameters of thecentral apertures 214, 217 may be the same as or slightly larger thanthe outer diameter of the motor shaft 220. The rotor assembly 208 formspart of a motor (not shown) having a stator assembly (not shown) that,when energized with a current, is adapted to induce rotation of therotor 212 and thus the motor shaft 220 about respective collinearrotational axes 219, 230.

The take-up reel assembly 204 includes a reel hub 232 baying acircumferential wall 236 with an outer surface 237 on which a tape pack(not shown) may be wound, in addition to a central wall or plate 238that may be generally perpendicularly disposed relative to thecircumferential wall 236. Furthermore, first and second flanges 240, 244may be respectively secured to first and second opposing sides 248, 252of the reel hub 232 (e.g., opposed sides of the circumferential wall236) that serve to contain the tape pack therebetween. Rotation of therotor 212 about its rotational axis 219 causes a corresponding rotationof the take-up reel assembly 204 about a corresponding rotational axis254 via the motor shaft 220, where the various rotational axes 219, 230,254 are collinear.

In contrast to previous designs that include various types of engagementfeatures that attempt to align and non-rotatably secure a rotor assemblyor other portion of a motor (e.g., motor shaft) to a separatelyfabricated reel hub, the arrangement 200 of FIG. 3 includes theintegrated assembly 218 which eliminates or at least limits the need forfasteners, gaps, and the like between the reel hub and the drive shaftof a motor. Specifically, the integrated assembly 218 includes the motorshaft 220 and the reel hub 232, where the reel hub 232 is directlymolded or otherwise initially fabricated directly over the motor shaft220 so as to form a single, integral, rigid piece with the motor shaft220. For instance, the central portion 256 of the reel hub 232 mayinclude a base wall 260 having an inner surface 261 that is adapted todirectly contact the first end 224 of the motor shaft 220. The centralportion 256 may also include a circumferential wall 264 having a surface265 that is adapted to directly contact the outer surface 221 of themotor shaft 220. Of note, the integrated assembly 218 may be free ofgaps or clearances between the central portion 256 of the reel hub 232and the motor shaft 220 which at least largely eliminates theabove-discussed tolerances of previous assemblies. Furthermore, theintegrated assembly 218 may be free of any fasteners extending betweenthe reel hub 232 and the rotor 212. In this regard, the various inherenttolerances associated with fabricating and aligning apertures on thecentral plate 238 of the reel hub 232 and the rotor 212 may beeliminated or at least limited.

Turning to FIG. 4, a method 300 of fabricating an integrated assembly(e.g., such as the integrated assembly 218 of FIG. 3) is illustrated. Inconjunction with a discussion of the fabrication method 300, referencewill also be made to the die or mold 400 of FIG. 5 which may be used aspart of the fabrication method 300 (portions of the mold 400 have beenremoved for clarity). At 304, a motor Shaft 404 may be positioned withinthe mold 400 so that an end 405 of a motor shaft 404 is positionedwithin a reel hub cavity 412 of the mold 400, where the reel hub cavity412 has a shape and dimensions of a desired reel hub to be fabricated(e.g., reel hub 232 of FIG. 3). The mold 400 may include a stationaryportion or platen 408 that makes up one side of the reel hub cavity 412and a movable portion or platen 409 that is movable along tie rods orthe like (not shown) towards the stationary platen 408 so as to exert aclamping pressure against resin passed (e.g., injected) into the reelhub cavity 412.

For instance, the movable platen 409 may include an elongated aperture411 having an inner diameter that is slightly larger than (e.g., on theorder of hundredths or thousandths of an inch) an outer diameter of themotor shaft 404 to allow the motor shaft 404 to be inserted andpositioned therein so that the motor shaft 404 is substantially free ofthe ability to move laterally within the aperture 411. In onearrangement, the inner diameter of the aperture 411 may be substantiallythe same as (e.g., slightly larger than) the inner diameter of thecentral aperture of the rotor into which the drive shaft 404 is to beplaced after the molding process (e.g., central apertures 214, 217 inFIG. 3). The movable platen 409 may also include a surface 413 formed ata bottom of the aperture 411 that is adapted to support the drive shaft404 (a second end 414 of the drive shaft 404 opposed to the end 405) ina manner so that the end 405 of the drive shaft 404 may protrude intothe reel hub cavity 412 when the movable platen 409 is moved andpositioned against or adjacent the stationary platen 408. In onearrangement, the reel hub cavity 412 may include a circumferential wallsection 416 (e.g., corresponding to circumferential wall 236 of FIG. 3),a central plate section 420 (e.g., corresponding to central plate 238 ofFIG. 3), and a central portion section 424 (e.g., corresponding tocentral portion 256 of FIG. 3). As shown, the end 405 of the drive shaft404 may be positioned within the central portion section 424 of the reelha cavity 412.

With reference back to FIG. 4, the method 300 may include injecting 308any appropriate resin into the reel hub cavity 412 so as to conic intodirect contact with the end 405 and circumferential sidewall 406 of themotor shaft 404. For instance, FIG. 5 illustrates a portion of a hotrunner system 432 that is design to store or contain resin (e.g., moltenplastic, not shown) received from a barrel (not shown). The hot runnersystem 432 may include a nozzle 436 positioned adjacent an opening 440into the reel hub cavity 412 so as to forcibly inject the resin intoeach of the circumferential wall section 416, central plate section 420,and central portion section 424 of the reel hub cavity 412 and intocontact with the end 405 and circumferential sidewall 406 of the motorshaft 404. While not shown, the hot runner system 432 and barrel mayinclude and/or be associated with any appropriate components that allowfor the forcible injection of the resin into the reel hub cavity 412(e.g., heater, hopper with. raw plastic, reciprocating screw, drivemotor, and the like).

At 312, the method 300 may include allowing the resin to cool and hardenwithin the reel huh cavity 412 about the end 406 and circumferentialsidewall 406 of the motor shaft 404 to create an integrated reel hub andmotor shaft assembly. In conjunction with allowing 312 the resin tocool, the movable platen 409 may be clamped against the stationaryplaten 408 so as to limit the high pressure injected resin from forcingthe stationary and movable platens 408, 409 apart before the resin hasfully cooled. At 316, the integrated assembly (e.g., the reel hub 232and motor shaft 220 of FIG. 3) may be removed from the mold 400. Forinstance, the movable platen 409 may be moved away from the stationaryplaten 408 and then the integrated assembly may be separated from themovable platen 409 via ejector pins 410 (see FIG. 5). Once theintegrated assembly has been removed from the mold, the central apertureof a rotor may be appropriate pressed over the drive shaft 404 so as tobe non-rotatable relative to the drive shaft 404. With reference to FIG.3, for instance the central apertures 214, 217 of the rotor part 213 andball bearing assembly 216 may be pressed over the drive shaft so thatthe inner surfaces of the central apertures 214, 217 are innon-rotatable contact with the outer surface of the drive shaft (e.g.,so that rotation of the rotor part 213 and ball bearing assembly 216causes a corresponding rotation of the drive shaft 220/404 and the reelhub 232. At any appropriate time, upper and lower flanges 240, 244 maybe appropriately secured to the reel hub 232 and the apparatus 200 maybe appropriately secured within a tape drive for acceptance of a tapepack.

Use of the mold 400 allows the end 405 and at least a portion of acircumferential sidewall 406 of the motor shaft 404 to be substantiallyprecisely centrally positioned within the central portion section 424 ofthe reel hub cavity 412, and thus the central portion 256 of the reelhub 232 to be formed. In one regard, integrally molding the reel hub 232onto the motor shaft 220 allows a longitudinal and rotational axis407/230 of the motor shaft 404/220 (as well as a rotational axis 219 ofrotor 212) to be perpendicularly oriented relative to a plane 428 alongwhich the central plate section 420 of the reel hub cavity 412 isaligned (and thus along which the central plate 238 of the reel hub 232is aligned). As a result, the central and circumferential walls 238, 236may be allowed to rotate or spin substantially free of wobble whichlimits nm-out of the tape pack as it is wound onto the take-up reel 204.Furthermore, the method 300 and/or mold 400 advantageously allow thereel hub 232 to be directly molded onto the motor shaft 220 in a mannerthat is free of fasteners, apertures, gaps, and the like which wouldotherwise inherently introduce a substantial tolerance stack-up leadingto axial and radial run-out of the tape pack and resultant errors inloading, tension, reading, writing, and the like.

It will be readily appreciated that many additions and/or deviations maybe made from the specific embodiments disclosed in the specificationwithout departing from the spirit and scope of the invention. Forinstance, while the disclosed integrated assembly has been discussedprimarily in the context of take-up reels for tape drives, it isenvisioned that the integrated assembly may be used to construct othertypes of reels or drums that are operable to accept tape packs (e.g.,magnetic, optical, and the like). Furthermore, while the disclosedmethod of manufacturing the integrated assembly was in the context of aninjection molding process, it will be readily appreciated that othertypes of processes may also be used (e.g., compression molding, resintransfer molding, and the like). The illustrations and discussion hereinhas only been provided to assist the reader in understanding the variousaspects of the present disclosure. Furthermore, one or more variouscombinations of the above discussed arrangements and embodiments arealso envisioned.

While this disclosure contains many specifics, these should not beconstrued as limitations on the scope of the disclosure or of what maybe claimed, but rather as descriptions of features specific toparticular embodiments of the disclosure. Furthermore, certain featuresthat are described in this specification in the context of separateembodiments can also be implemented in combination in a singleembodiment. Conversely, various features that are described in thecontext of a single embodiment can also be implemented in multipleembodiments separately or in any suitable subcombination. Moreover,although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, multitasking and/or parallelprocessing may be advantageous. Moreover, the separation of varioussystem components in the embodiments described above should not beunderstood as requiring such separation. in all embodiments, and itshould be understood that the described program components and systemscan generally be integrated together in a single software and/orhardware product or packaged into multiple software and/or hardwareproducts.

The above described embodiments including the preferred embodiment andthe best mode of the invention known to the inventor at the time offiling are given by illustrative examples only.

We claim:
 1. A method of fabricating an apparatus for use in a tapedrive, comprising: providing a motor shaft having first and second endsand a rotational axis extending between the first and second ends; andmolding a hub of a reel assembly to the first end of the motor shaft toform an integral piece with the motor shaft, wherein after the molding,the hub comprises: an outer circumferential surface that is adapted toreceive a tape pack thereon; and a rotational axis that is collinearwith the rotational axis of the motor shaft.
 2. The method of claim 1,further comprising: positioning the motor shaft within a mold so thatthe first end of the motor shaft is positionable within a huh cavity ofthe mold.
 3. The method of claim 2, wherein the mold comprises astationary platen and a movable platen that is movable towards and awayfrom the stationary platen, wherein the hub cavity is disposed betweenthe stationary and movable platens, and wherein the positioningcomprises: inserting the motor shaft into an aperture in the movableplaten; and moving the movable platen relative to the stationary platento position the first end of the motor shaft within the hub cavity. 4.The method of claim 3, wherein the inserting comprises: inserting themotor shaft into the aperture in the movable platen until a second endof the motor shaft contacts a bottom surface of the aperture.
 5. Themethod of claim 2, wherein the molding comprises: injecting resin intothe hub cavity; and allowing the resin to harden, wherein the injectingand allowing collectively define an injection molding process, andwherein the hardened resin comprises the hub.
 6. The method of claim 5,further comprising: removing the integral piece from the mold; andpressing a central aperture of a rotor over the motor shaft of theintegral piece.
 7. The method of claim 2, wherein the mold isconstructed of steel.
 8. The method of claim 1, wherein the hub furthercomprises first and second laterally opposed sides, and wherein themethod further comprises: securing a first flange member to the firstopposed side of the hub; and securing a second flange member to thesecond opposed side of the hub, wherein the first and second flangemembers are adapted to contain the tape pack therebetween.
 9. A method,comprising: securing the integral piece of claim 1 within a tape drive.10. The method of claim. 9, further comprising: using the motor shaft torotate the hub about its rotational axis; and taking-up tape on theouter circumferential surface of the hub.
 11. An apparatus for a tapedrive, comprising: a motor shaft having first and second ends and arotational axis extending between the first and second ends, wherein themotor shaft is adapted to be rotated about the rotational axis by amotor; and a reel hub having an outer circumferential surface, a centralportion, and a rotational axis that is collinear with the rotationalaxis of the motor shaft and that passes through the central portion,wherein the outer circumferential surface is adapted to receive a tapepack thereon, and wherein the central portion of the reel hub comprisesan inner surface that is in direct and rigid contact with the first endof the motor shaft.
 12. The apparatus of claim 11, further comprising: arotor comprising a central aperture and a rotational axis passingthrough the central aperture, wherein the motor shaft is non-rotatablysecured to the rotor via the central aperture, wherein the rotationalaxes of the rotor, motor shaft and hub are all collinear, and whereinrotation of the rotor via a corresponding stator assembly induces acorresponding rotation of the reel hub via the motor shaft.
 13. Theapparatus of claim 11, wherein the reel hub further comprises first andsecond opposed laterally opposed sides, and wherein the apparatusfurther comprises: a first flange member secured to the first opposedside of the hub; and a second flange member secured to the secondopposed side of the huh, wherein the first and second flange members areadapted to contain the tape pack therebetween.
 14. The apparatus ofclaim 11, wherein the motor shaft comprises an outer circumferentialsurface extending between the first and second ends, and wherein thecentral portion of the reel hub is molded onto at least a portion of theouter circumferential surface of the motor shaft.
 15. The apparatus ofclaim 11, wherein the apparatus is free of gaps between the centralportion of the reel hub and the motor shaft.
 16. The apparatus of claim11, wherein the central portion of the reel hub is directly molded ontothe first end of the motor shaft to provide the direct and rigidcontact.
 17. A tape drive, comprising: a housing; a motor thatcomprises: a stator non-rotatably secured to the housing; and a rotorrotatably interconnected to the stator; a motor shaft non-rotatablysecured to the rotor; and a reel hub that is adapted to receive a tapepack thereon, wherein the reel hub is molded directly onto an end of themotor shaft, wherein passing a current through a conductor of the motorgenerates a force that rotates the rotor, and wherein rotation of therotor induces a corresponding rotation of the reel hub via the motorshaft.
 18. The tape drive of claim 17, wherein the tape drive is free offasteners securing the reel hub to the motor and free of gaps betweenthe central portion of the reel hub and the motor shaft.
 19. The tapedrive of claim 17, further comprising: a first flange member secured toa first side of the reel hub; and a second flange member secured to asecond opposed side of the reel hub, wherein the first and second flangemembers are adapted to contain the tape pack therebetween.
 20. The tapedrive of claim 19, wherein the first flange member, second flange memberand reel huh collectively define a take-up reel that is adapted toaccept the tape pack from a cartridge reel.